Use of aqueous hybrid binders and alkyd systems for coating agents

ABSTRACT

The present invention relates to aqueous hybrid binders comprising an aqueous polymer dispersion (PD), and also 0.01%-5% by weight of a photoinitiator, and also to aqueous alkyd systems comprising a water-soluble alkyd resin or an aqueous alkyd or polyurethane emulsion or dispersion, and also 0.01%-5% by weight of a photoinitiator, and to the use thereof in coating compositions, more particularly in coating materials.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of PCT/EP2013/063035 filed on Jun. 21, 2013. This application is based upon and claims the benefit of priority to European Application No. 12175345.3 filed on Jul. 6, 2012.

The present invention relates to aqueous hybrid binders comprising an aqueous polymer dispersion (PD), and also 0.01%-5% by weight of a photoinitiator, and also to aqueous alkyd systems comprising a water-soluble alkyd resin or an aqueous alkyd or polyurethane-alkyd emulsion or dispersion, and also 0.01%-5% by weight of a photoinitiator, and to the use thereof in coating compositions, more particularly in coating materials.

Water-based alkyds and corresponding alkyd/acrylate hybrids in coating materials (more particularly in gloss paints) under standard conditions do not exhibit optimum development of hardness—that is, such paints often stay soft and sticky for too long after they have been applied to a substrate. The necessary development of hardness comes about through oxidative crosslinking of the alkyds, or of the alkyd fraction, and takes place under the influence of atmospheric oxygen. In the case of water-based systems, however, this kind of crosslinking is rather slow in comparison to solvent-based paints. In the hybrid systems in particular it is even more problematic, since the fraction of crosslinking groups is smaller. In order to accelerate this crosslinking it is possible to use siccatives. If oxidative drying has to proceed rapidly, as is often desirable, it is necessary to use relatively large amounts of these siccatives or dryers. A serious drawback of these substances, however, is that they are based on heavy metals and, depending on the nature of the metal used, they lower the eco-friendliness of the paint (see also U. Poth, Polyester and Alkydharze, ISBN 3-87870-792-4). If relatively large amounts of siccatives are used, an additional drawback is that the pot life and shelf life of the paint are reduced: as soon as there is contact with atmospheric oxygen, the paint begins to crosslink even in its container.

US 2008/0287581 describes an aqueous polymer dispersion comprising a zinc-modified polymer and the use thereof in coating materials. Here, the zinc-containing component takes over the function of the siccatives.

EP 2 009 072 describes an aqueous polymer composition comprising acetoacetoxyethyl (meth)acrylate (AAEM) for decorative and protective coatings that comprises 8-35% of an autoxidizable material (e.g., an alkyd) as a result of cold blending or of addition during formulation. Nothing is said therein about hardness development and its extent.

EP 874 875 discloses a hybrid binder composition based on water and its use as a component in a paint or varnish mixture, the hybrid binder composition possessing a dry matter fraction of 60% to 95% by weight.

WO 2010/040844 describes hybrid binders prepared by means of a miniemulsion polymerization process. The formulated paint systems have been admixed with conventional siccatives in order that an acceptable development of hardness can take place in the coatings.

WO 2010/112474 describes methacrylate polymers prepared by means of emulsion polymerization, comprising (meth)acrylate monomers having oxidatively crosslinkable side groups. Through preferred use of copolymerizable photoinitiators it has been possible to achieve a good development of hardness in the coating after UV irradiation.

Coating compositions which comprise reactive groups and are cured by UV radiation are known from WO 98/033855. A drawback of such systems is that they have to be cured by UV irradiation with very high irradiation energies in the absence of atmospheric oxygen. Without these high light energies, or in the presence of oxygen, the quality of the corresponding coatings is insufficient.

The compositions of the prior art have the disadvantage that in coating materials under standard conditions they do not exhibit optimum development of hardness, and such paints remain soft and sticky for too long unless siccatives based on heavy metals are used or UV curing takes place.

The object of the invention, therefore, was to develop a binder which features improved early hardness development.

In accordance with the invention the object has been achieved by means of an aqueous hybrid binder comprising an aqueous polymer dispersion (PD), and also 0.01%-5% by weight of a photoinitiator, and also by aqueous alkyd systems comprising a water-soluble alkyd resin or an aqueous alkyd or polyurethane-alkyd emulsion or dispersion, and also 0.01%-5% by weight of a photoinitiator. No additional irradiation is needed to cure the films comprising the hybrid binders of the invention or the aqueous alkyd systems.

The aqueous polymer dispersion (PD) is obtainable by free-radical emulsion polymerization of

-   (a) at least one α,β-ethylenically unsaturated monomer (M), -   (b) and also, optionally, at least one further monomer (M1), to give     a polymer (P), -   (c) optionally, subsequent chemical deodorization and -   (d) addition of at least one water-soluble alkyd resin having a     weight-average molecular weight of between 5000 and 40 000 Da, or of     at least one aqueous alkyd or polyurethane-alkyd emulsion,     wherein the addition of the alkyd resin, alkyd or polyurethane-alkyd     emulsion or dispersion takes place alternatively     -   i. subsequent to the polymerization of M and M1, and optionally         the chemical deodorization, at room temperature,     -   ii. subsequent to the polymerization of M and M1, with an         afterstir time of 0-2 h, or     -   iii. subsequent to the chemical deodorization, with an afterstir         time of 0-2 h, the temperature in the case of addition according         to (ii) or (iii) being 60 to 99° C., preferably 70 to 95° C.,         and more particularly 80 to 90° C.

The invention further provides coating compositions, more particularly coating materials, comprising the hybrid binders of the invention and/or the aqueous alkyd systems, and also the preparation and use thereof.

The invention further provides coating compositions in the form of an aqueous composition comprising:

-   -   at least one inventive hybrid binder or an aqueous alkyd system,         as defined below,     -   optionally, at least one inorganic filler and/or inorganic         pigment,     -   customary auxiliaries, and     -   water to 100% by weight.

The hybrid binder of the invention comprises the polymer dispersion (PD) of the invention and also 0.01%-5% by weight of a photoinitiator.

The aqueous alkyd system of the invention comprises at least one water-soluble alkyd resin or an aqueous alkyd or polyurethane-alkyd emulsion or dispersion, and also 0.01%-5% by weight of a photoinitiator.

The addition of the water-soluble alkyd resin or of the aqueous alkyd or polyurethane-alkyd emulsion or dispersion to the polymer dispersion (PD) is made preferably after the emulsion polymerization for preparing the polymer (P). The addition of the water-soluble alkyd resin or of the aqueous alkyd emulsion or polyurethane-alkyd emulsion to the polymer dispersion (PD) may take place directly subsequent to the polymerization, i.e., directly after the end of the initiator feed. The addition preferably takes place after the end of the polymerization and of the afterstir time as defined above. With particular preference the addition is made after the chemical deodorization. With very particular preference the addition is made after the chemical deodorization, including the above-defined afterstir time. The afterstir time is 0 to 2 h, preferably less than 1 h, more preferably 30 min.

The addition of the photoinitiator for preparing the hybrid binder of the invention is made preferably to the polymer dispersion (PD) which has been cooled to room temperature (23° C.), but may also be made during the polymerization.

For preparing the aqueous alkyd system, the photoinitiator is added at room temperature to the water-soluble alkyd resin or to the aqueous alkyd or polyurethane-alkyd emulsion or dispersion.

The photoinitiator of the invention is used in amounts of 0.01%-5% by weight, preferably 0.1%-4% by weight, based in each case on the solids content of the hybrid binder or of the aqueous alkyd system.

Early hardness development is understood to be the increase of hardness in the film within the first period of time following application (up to 3 days). It is measured via the pendulum hardness. It can be accelerated by siccativization.

The polymer dispersion (PD) used in accordance with the invention comprises preferably 5-60% by weight (solids), more preferably 10-50% by weight (solids), based on the total weight of the hybrid binder, of at least one water-soluble alkyd resin or an aqueous alkyd emulsion or polyurethane-alkyd emulsion.

The inventive use of the water-soluble alkyd resins or of the aqueous alkyd or polyurethane-alkyd emulsions or dispersions is accompanied by the following advantage:

-   -   increase in the gloss of coating compositions (coating         materials), especially of gloss paints based on acrylate         dispersions, with a simultaneously (in comparison to other         hybridization methods) reduced amount of residual acrylate         monomers.

In the context of the present invention the expression “alkyl” comprises straight-chain and branched alkyl groups. Suitable short-chain alkyl groups are, for example, straight-chain or branched C₁-C₇ alkyl, preferably C₁-C₆ alkyl, and more preferably C₁-C₄ alkyl groups. They include more particularly methyl, ethyl, propyl, isopropyl, n-butyl, 2-butyl, sec-butyl, tert-butyl, n-pentyl, 2-pentyl, 2-methylbutyl, 3-methylbutyl, 1,2-dimethylpropyl, 1,1-dimethylpropyl, 2,2-dimethylpropyl, 1-ethylpropyl, n-hexyl, 2-hexyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 1,2-dimethylbutyl, 1,3-dimethylbutyl, 2,3-dimethylbutyl, 1,1-dimethylbutyl, 2,2-dimethylbutyl, 3,3-dimethylbutyl, 1,1,2-trimethylpropyl, 1,2,2-trimethylpropyl, 1-ethylbutyl, 2-ethylbutyl, 1-ethyl-2-methylpropyl, n-heptyl, 2-heptyl, 3-heptyl, 2-ethylpentyl, 1-propylbutyl, etc.

Suitable longer-chain C₈-C₃₀ alkyl groups are straight-chain and branched alkyl groups. They are preferably predominantly linear alkyl radicals, of the kind also occurring in natural or synthetic fatty acids and fatty alcohols and also oxo-process alcohols. They include, for example, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, n-tridecyl, n-tetradecyl, n-pentadecyl, n-hexadecyl, n-heptadecyl, n-octadecyl, n-nonadecyl, etc. The expression “alkyl” comprises unsubstituted and substituted alkyl radicals.

The above remarks for alkyl also apply to the alkyl moieties in arylalkyl. Preferred arylalkyl radicals are benzyl and phenylethyl.

C₈-C₃₂ alkenyl in the context of the present invention stands for straight-chain and branched alkenyl groups, which may be singly, doubly or multiply unsaturated. Preference is given to C₁₀-C₂₀ alkenyl. The expression “alkenyl” comprises unsubstituted and substituted alkenyl radicals. The radicals in question are, especially, predominantly linear alkenyl radicals, of the kind which also occur in natural or synthetic fatty acids and fatty alcohols and also oxo-process alcohols. They include more particularly octenyl, nonenyl, decenyl, undecenyl, dodecenyl, tridecenyl, tetradecenyl, pentadecenyl, hexadecenyl, heptadecenyl, octadecenyl, nonadecenyl, linolyl, linolenyl, eleostearyl, and oleyl (9-octadecenyl).

The expression “alkylene” in the sense of the present invention stands for straight-chain or branched alkanediyl groups having 1 to 7 carbon atoms, such as methylene, 1,2-ethylene, 1,3-propylene, etc.

Cycloalkyl stands preferably for C₄-C₈ cycloalkyl, such as cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl.

The expression “aryl” comprises for the purposes of the present invention monocyclic or polycyclic aromatic hydrocarbon radicals which may be unsubstituted or substituted. The expression “aryl” stands preferably for phenyl, tolyl, xylyl, mesityl, duryl, fluorenyl, anthracenyl, phenanthrenyl or naphthyl, more preferably for phenyl or naphthyl, it being possible for these aryl groups, in the case of substitution, to carry generally 1, 2, 3, 4 or 5, preferably 1, 2 or 3, substituents.

The polymer dispersion (PD) is prepared using at least one α,β-ethylenically unsaturated monomer (M), which is preferably selected from esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with C₁-C₂₀ alkanols, vinylaromatics, esters of vinyl alcohol with C₁-C₃₀ monocarboxylic acids, ethylenically unsaturated nitriles, vinyl halides, vinylidene halides, monoethylenically unsaturated carboxylic and sulfonic acids, phosphorus monomers, esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with C₂-C₃₀ alkanediols, amides of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with C₂-C₃₀ amino alcohols which contain a primary or secondary amino group, primary amides of α,β-ethylenically unsaturated monocarboxylic acids and their N-alkyl and N,N-dialkyl derivatives, N-vinyllactams, open-chain N-vinylamide compounds, esters of allyl alcohol with C₁-C₃₀ monocarboxylic acids, esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with amino alcohols, amides of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with diamines which contain at least one primary or secondary amino group, N,N-diallylamines, N,N-diallyl-N-alkylamines, vinyl- and allyl-substituted nitrogen heterocycles, vinyl ethers, C₂-C₈ monoolefins, nonaromatic hydrocarbons having at least two conjugated double bonds, polyether (meth)acrylates, monomers containing urea groups, and mixtures thereof.

Suitable esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with C₁-C₂₀ alkanols are methyl (meth)acrylate, methyl ethacrylate, ethyl (meth)acrylate, ethyl ethacrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, sec-butyl (meth)acrylate, tert-butyl (meth)acrylate, tert-butyl ethacrylate, n-hexyl (meth)acrylate, n-heptyl (meth)acrylate, n-octyl (meth)acrylate, 1,1,3,3-tetramethylbutyl (meth)acrylate, ethylhexyl (meth)acrylate, n-nonyl (meth)acrylate, n-decyl (meth)acrylate, n-undecyl (meth)acrylate, tridecyl (meth)acrylate, myristyl (meth)acrylate, pentadecyl (meth)acrylate, palmityl (meth)acrylate, heptadecyl (meth)acrylate, nonadecyl (meth)acrylate, arachinyl (meth)acrylate, behenyl (meth)acrylate, lignoceryl (meth)acrylate, cerotinyl (meth)acrylate, melissinyl (meth)acrylate, palm itoleyl (meth)acrylate, oleyl (meth)acrylate, linolyl (meth)acrylate, linolenyl (meth)acrylate, stearyl (meth)acrylate, lauryl (meth)acrylate, and mixtures thereof.

Preferred vinylaromatics are styrene, 2-methylstyrene, 4-methylstyrene, 2-(n-butyl)styrene, 4-(n-butyl)styrene, 4-(n-decyl)styrene, and, with particular preference, styrene.

Suitable esters of vinyl alcohol with C₁-C₃₀ monocarboxylic acids are, for example, vinyl formate, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl laurate, vinyl stearate, vinyl propionate, Versatic acid vinyl esters, and mixtures thereof.

Suitable ethylenically unsaturated nitriles are acrylonitrile, methacrylonitrile, and mixtures thereof.

Suitable vinyl halides and vinylidene halides are vinyl chloride, vinylidene chloride, vinyl fluoride, vinylidene fluoride, and mixtures thereof.

Suitable ethylenically unsaturated carboxylic acids and sulfonic acids or their derivatives are acrylic acid, methacrylic acid, ethacrylic acid, α-chloroacrylic acid, crotonic acid, maleic acid, maleic anhydride, itaconic acid, citraconic acid, mesaconic acid, glutaconic acid, aconitic acid, fumaric acid, the monoesters of monoethylenically unsaturated dicarboxylic acids having 4 to 10, preferably 4 to 6, C atoms, e.g., monomethyl maleate, vinylsulfonic acid, allylsulfonic acid, sulfoethyl acrylate, sulfoethyl methacrylate, sulfopropyl acrylate, sulfopropyl methacrylate, 2-hydroxy-3-acryloyloxypropylsulfonic acid, 2-hydroxy-3-methacryloyloxypropylsulfonic acid, styrenesulfonic acids, and 2-acrylamido-2-methylpropanesulfonic acid. Suitable styrenesulfonic acids and derivatives thereof are styrene-4-sulfonic acid and styrene-3-sulfonic acid and the alkali metal or alkaline earth metal salts thereof, such as sodium styrene-3-sulfonate and sodium styrene-4-sulfonate, for example. Particularly preferred are acrylic acid, methacrylic acid, and mixtures thereof.

Examples of phosphorus monomers are vinylphosphonic acid and allylphosphonic acid, for example. Also suitable are the monoesters and diesters of phosphonic acid and phosphoric acid with hydroxyalkyl (meth)acrylates, especially the monoesters. Additionally suitable are diesters of phosphonic acid and phosphoric acid that have been esterified once with a hydroxyalkyl (meth)acrylate and also once with a different alcohol, such as an alkanol, for example. Suitable hydroxyalkyl (meth)acrylates for these esters are those specified below as separate monomers, more particularly 2-hydroxyethyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, etc. Corresponding dihydrogen phosphate ester monomers comprise phosphoalkyl (meth)acrylates, such as 2-phosphoethyl (meth)acrylate, 2-phosphopropyl (meth)acrylate, 3-phosphopropyl (meth)acrylate, phosphobutyl (meth)acrylate, and 3-phospho-2-hydroxypropyl (meth)acrylate. Also suitable are the esters of phosphonic acid and phosphoric acid with alkoxylated hydroxyalkyl (meth)acrylates, examples being the ethylene oxide condensates of (meth)acrylates, such as H₂C═C(CH₃)COO(CH₂CH₂O)_(n)P(OH)₂ and H₂C═C(CH₃)COO(CH₂CH₂O)_(n)P(═O)(OH)₂, in which n is 1 to 50. Of further suitability are phosphoalkyl crotonates, phosphoalkyl maleates, phosphoalkyl fumarates, phosphodialkyl (meth)acrylates, phosphodialkyl crotonates and allyl phosphates. Further suitable monomers containing phosphorus groups are described in WO 99/25780 and U.S. Pat. No. 4,733,005, hereby incorporated by reference.

Suitable esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with C₂-C₃₀ alkanediols are, for example, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxyethyl ethacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropyl acrylate, 3-hydroxypropyl methacrylate, 3-hydroxybutyl acrylate, 3-hydroxybutyl methacrylate, 4-hydroxybutyl acrylate, 4-hydroxybutyl methacrylate, 6-hydroxyhexyl acrylate, 6-hydroxyhexyl methacrylate, 3-hydroxy-2-ethylhexyl acrylate, 3-hydroxy-2-ethylhexyl methacrylate, etc.

Suitable primary amides of α,β-ethylenically unsaturated monocarboxylic acids and their N-alkyl and N,N-dialkyl derivatives are acrylamide, methacrylamide, N-methyl(meth)acrylamide, N-ethyl(meth)acrylamide, N-propyl(meth)acrylamide, N-(n-butyl)(meth)acrylamide, N-(tert-butyl)(meth)acrylamide, N-(n-octyl)(meth)acrylamide, N-(1,1,3,3-tetramethylbutyl)(meth)acrylamide, N-ethylhexyl(meth)acrylamide, N-(n-nonyl)(meth)acrylamide, N-(n-decyl)(meth)acrylamide, N-(n-undecyl)(meth)acrylamide, N-tridecyl(meth)acrylamide, N-myristyl(meth)acrylamide, N-pentadecyl(meth)acrylamide, N-palmityl(meth)acrylamide, N-heptadecyl(meth)acrylamide, N-nonadecyl(meth)acrylamide, N-arachidyl(meth)acrylamide, N-behenyl(meth)acrylamide, N-lignoceryl(meth)acrylamide, N-cerotinyl(meth)acrylamide, N-melissinyl(meth)acrylamide, N-palmitoleyl(meth)acrylamide, N-oleyl(meth)acrylamide, N-linolyl(meth)acrylamide, N-linolenyl(meth)acrylamide, N-stearyl(meth)acrylamide, N-lauryl(meth)acrylamide, N,N-dimethyl(meth)acrylamide, N,N-diethyl(meth)acrylamide, morpholinyl(meth)acrylamide.

Suitable N-vinyllactams and their derivatives are, for example, N-vinylpyrrolidone, N-vinylpiperidone, N-vinylcaprolactam, N-vinyl-5-methyl-2-pyrrolidone, N-vinyl-5-ethyl-2-pyrrolidone, N-vinyl-6-methyl-2-piperidone, N-vinyl-6-ethyl-2-piperidone, N-vinyl-7-methyl-2-caprolactam, N-vinyl-7-ethyl-2-caprolactam, etc.

Suitable open-chain N-vinylamide compounds are, for example, N-vinylformamide, N-vinyl-N-methylformamide, N-vinylacetamide, N-vinyl-N-methylacetamide, N-vinyl-N-ethylacetamide, N-vinylpropionamide, N-vinyl-N-methylpropionamide, and N-vinylbutyramide.

Suitable esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with amino alcohols are N,N-dimethylaminomethyl (meth)acrylate, N,N-dimethylaminoethyl (meth)acrylate, N,N-diethylaminoethyl acrylate, N,N-dimethylaminopropyl (meth)acrylate, N,N-diethylaminopropyl (meth)acrylate, and N,N-dimethylaminocyclohexyl (meth)acrylate.

Suitable amides of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with diamines which contain at least one primary or secondary amino group are N-[2-(dimethylamino)ethyl]acrylamide, N-[2-(dimethylamino)ethyl]methacrylamide, N-[3-(dimethylamino)propyl]acrylamide, N-[3-(dimethylamino)propyl]methacrylamide, N-[4-(dimethylamino)butyl]acrylamide, N-[4-(dimethylamino)butyl]methacrylamide, N-[2-(diethylamino)ethyl]acrylamide, N-[4-(dimethylamino)cyclohexyl]acrylamide, N-[4-(dimethylamino)cyclohexyl]methacrylamide, etc.

Suitable monomers (M) are, furthermore, N,N-diallylamines and N,N-diallyl-N-alkylamines and their acid addition salts and quaternization products. Alkyl here is preferably C₁-C₂₄ alkyl. Preference is given to N,N-diallyl-N-methylamine and to N,N-diallyl-N,N-dimethylammonium compounds, such as the chlorides and bromides, for example.

Further suitable monomers (M) are vinyl- and allyl-substituted nitrogen heterocycles, such as N-vinylimidazole, N-vinyl-2-methylimidazole, and vinyl- and allyl-substituted heteroaromatic compounds, such as 2- and 4-vinylpyridine, 2- and 4-allylpyridine, and the salts thereof.

Suitable C₂-C₈ monoolefins and nonaromatic hydrocarbons having at least two conjugated double bonds are for example ethylene, propylene, isobutylene, isoprene, butadiene, etc.

Examples of suitable monomers containing urea groups are N-vinylurea or N-allylurea or derivatives of imidazolidin-2-one. They include N-vinyl- and N-allylimidazolidin-2-one, N-vinyloxyethylimidazolidin-2-one, N-(2-(meth)acrylamidoethyl)imidazolidin-2-one, N-(2-(meth)acryloxyethyl)imidazolidin-2-one (i.e., 2-ureido (meth)acrylate), N-[2-((meth)acryloxyacetamido)ethyl]imidazolidin-2-one, etc.

Preferred monomers containing urea groups are N-(2-acryloxyethyl)imidazolidin-2-one and N-(2-methacryloxyethyl)imidazolidin-2-one. Particular preference is given to N-(2-methacryloxyethyl)imidazolidin-2-one (2-ureido methacrylate, UMA).

The aforementioned monomers (M) may be used individually, in the form of mixtures within one class of monomer, or in the form of mixtures from different classes of monomer.

For the emulsion polymerization it is preferred to use at least 40%, more preferably at least 60%, and more particularly at least 80% by weight, based on the total weight of the monomers M), of at least one monomer M1) selected from esters of α,β-ethylenically unsaturated monocarboxylic and dicarboxylic acids with C₁-C₂₀ alkanols, vinylaromatics, esters of vinyl alcohol with C₁-C₃₀ monocarboxylic acids, ethylenically unsaturated nitriles, vinyl halides, vinylidene halides, and mixtures thereof (principal monomers). Preferably the monomers (M1) are used for the emulsion polymerization in an amount of up to 95% by weight, based on the total weight of the monomers (M).

The principal monomers (M1) are preferably selected from methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, sec-butyl (meth)acrylate, tert-butyl (meth)acrylate, n-pentyl (meth)acrylate, n-hexyl (meth)acrylate, n-heptyl (meth)acrylate, n-octyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, isobornyl (meth)acrylate, styrene, 2-methylstyrene, vinyl acetate, acrylonitrile, methacrylonitrile, and mixtures thereof.

In addition to at least one principal monomer (M1) it is possible in the free-radical emulsion polymerization for the preparation of (PD) to use at least one further monomer (M2), which is generally present in a minor amount (secondary monomers). For the emulsion polymerization it is preferred to use up to 60%, more preferably up to 40%, and more particularly up to 20% by weight, based on the total weight of the monomers (M), of at least one monomer (M2) selected from ethylenically unsaturated monocarboxylic and dicarboxylic acids and the anhydrides and monoesters of ethylenically unsaturated dicarboxylic acids, (meth)acrylamides, C₁-C₁₀ hydroxyalkyl (meth)acrylates, C₁-C₁₀ hydroxyalkyl(meth)acrylamides, and mixtures thereof. Preferably the monomers (M2), when present, are used for the emulsion polymerization in an amount of at least 0.1% by weight, more preferably at least 0.5% by weight, more particularly at least 1% by weight, based on the total weight of the monomers (M).

For the emulsion polymerization it is particularly preferred to use 0.1% up to 60%, preferably 0.5% to 40%, more particularly 1% to 20% by weight of at least one monomer (M2). The monomers (M2) are especially selected from acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, maleic anhydride, acrylamide, methacrylamide, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxyethylacrylamide, 2-hydroxyethylmethacrylamide, acetoacetoxyethyl methacrylate (AAEM), allyl methacrylate, vinyl methacrylate, hydroxybutenyl methacrylate, allyl or diallyl esters of maleic acid, poly(allyl glycidyl ether), and mixtures thereof, in the form of various products bearing the name Bisomer® from Laporte Performance Chemicals, UK. These include, for example, Bisomer® MPEG 350 MA, a methoxypolyethylene glycol monomethacrylate, or UMA. More particular preference is given to using AAEM in amounts of 0.1% to 20%, preferably of 0.1% to 4.9% by weight.

Particularly suitable combinations of principal monomers (M1) for the process of the invention are, for example:

n-butyl acrylate, methyl methacrylate;

n-butyl acrylate, methyl methacrylate, styrene;

n-butyl acrylate, styrene, butyl (meth)acrylate;

n-butyl acrylate, ethylhexyl acrylate, styrene;

n-butyl acrylate, styrene; or

n-butyl acrylate, n-butyl (meth)acrylate, methyl methacrylate.

The aforementioned particularly suitable combinations of principal monomers (M1) can be combined with particularly suitable monomers (M2), which are preferably selected from acrylic acid, methacrylic acid, acrylamide, methacrylamide, AAEM, UMA or Bisomer®, and mixtures thereof.

An alkyd resin is understood to be a polyester which is esterified with a drying oil, a fatty acid or the like (U. Poth, Polyester und Alkydharze, Vincentz Network 2005).

An aqueous alkyd resin is understood more particularly to be an alkyd resin solution which can be diluted with water—possibly after neutralization—and which is based on an alkyd resin having a sufficiently high acid number of preferably 20-80 mg KOH/g alkyd resin solids, and having a weight-average molecular weight of >5000 and <40 000 Da, preferably >8000 and <35 000 Da, and more preferably >10 000 and <35 000 Da.

The molecular weights are determined by size exclusion chromatography (SEC).

By acid number is meant the amount of potassium hydroxide, expressed in mg, which is needed in order to neutralize 1 g of the sample.

The oil used, or the fatty acid, is the property-determining component. It allows subdivision according to the fatty acid triacylglycerol content (oil content, oil length), into short-oil alkyd resins with <40%, medium-oil alkyd resins with 40-60%, and long-oil alkyd resins with >60% triacylglycerol, based on solvent-free alkyd resin (converting fatty acid content to triacylglycerol if necessary, factor approximately 1.045) (oil content).

In accordance with general practice, the solids content characterizes the “active ingredient content” of the dispersion. The dispersion is typically dried to constant weight at a temperature between 100 and 140° C. (see ISO standard 1625). The solids content indicates the dry mass in comparison to the total mass (in %).

The dry mass comprises the polymer, emulsifiers, and inorganic salts (from initiator decomposition and neutralization). The volatile constituents include the water and those monomers which have not reacted during the polymerization.

the alkyd resins used is 25-55%, the solids content is 30-80% in the supply form and 35-50% in the use form (following dilution with NH₃ and/or NaOH/water).

Examples of preferred alkyd resins are the products WorléeSol® 61A, WorléeSol® 61E, WorléeSol® 65A from Worlée, and Synthalat® W46 or Synthalat® W48, from Synthopol.

An aqueous alkyd resin emulsion or dispersion, or alkyd emulsion for short, is understood to refer to alkyd resins which, possibly with addition of emulsifiers, are dispersed in water. In comparison to water-soluble or dilutable alkyd resins, suitability for this purpose is also possessed by alkyds having relatively high average molar masses [U. Poth, Polyester und Alkydharze, Vincentz Network 2005, p. 183 f.].

An aqueous polyurethane-alkyd resin emulsion is understood to be a polyurethane-modified alkyd resin which has been dispersed in water. Urethane modification may take place in the course of alkyd synthesis, for example, by the replacement of some of the customary phthalic anhydride by a diisocyanate [U. Poth, Polyester and Alkydharze, Vincentz Network 2005, p. 205 f.]. Urethane modification may additionally be accomplished by reaction of an alkyd with an at least difunctional polyisocyanate [DE 102006054237].

Preferred alkyd resin emulsions feature an oil content of 25-55% and an acid number of 20-60 mg KOH/g.

Preferred alkyd resin emulsions and polyurethane-modified alkyd resin emulsions are WorléeSol® E 150 W, WorléeSol® E 280 W, WorléeSol® E 530 W or WorléeSol® E 927 W.

For preparing the polymer dispersion (PD) it is preferred to use aqueous alkyd emulsions or polyurethane-alkyd emulsions.

In the preparation of the polymer dispersions of the invention it is possible to use at least one crosslinker in addition to the aforementioned monomers (M). Monomers which possess a crosslinking function are compounds having at least two polymerizable, ethylenically unsaturated, nonconjugated double bonds in the molecule. Crosslinking may also take place, for example, through photochemical activation. For that purpose it is possible to prepare (PD) additionally using at least one monomer containing photoactivable groups. Photoinitiators can also be added separately. Crosslinking can also be accomplished, for example, by means of functional groups which are able to enter into a chemical crosslinking reaction with complementary functional groups. In that case the complementary groups may both be attached to the emulsion polymer or for the crosslinking it is possible to use a crosslinker which is capable of being able to enter into a chemical crosslinking reaction with functional groups of the emulsion polymer.

Suitable crosslinkers are, for example, acrylic esters, methacrylic esters, allyl ethers or vinyl ethers of at least dihydric alcohols. The OH groups of the parent alcohols may be wholly or partly etherified or esterified; the crosslinkers, however, comprise at least two ethylenically unsaturated groups.

Examples of the parent alcohols are dihydric alcohols such as 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 2,3-butanediol, 1,4-butanediol, but-2-ene-1,4-diol, 1,2-pentanediol, 1,5-pentanediol, 1,2-hexanediol, 1,6-hexanediol, 1,10-decanediol, 1,2-dodecanediol, 1,12-dodecanediol, neopentyl glycol, 3-methylpentane-1,5-diol, 2,5-dimethyl-1,3-hexanediol, 2,2,4-trimethyl-1,3-pentanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,4-bis(hydroxymethyl)cyclohexane, hydroxypivalic acid neopentyl glycol monoester, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis[4-(2-hydroxypropyl)phenyl]propane, diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, tetrapropylene glycol, 3-thiapentane-1,5-diol, and also polyethylene glycols, polypropylene glycols, and polytetrahydrofurans having molecular weights of in each case 200 to 10 000. Besides the homopolymers of ethylene oxide or propylene oxide it is also possible to use block copolymers of ethylene oxide or propylene oxide, or copolymers which incorporate ethylene oxide and propylene oxide groups. Examples of parent alcohols having more than two OH groups are trimethylolpropane, glycerol, pentaerythritol, 1,2,5-pentanetriol, 1,2,6-hexanetriol, cyanuric acid, sorbitan, sugars such as sucrose, glucose, and mannose. The polyhydric alcohols can of course also be used, following reaction with ethylene oxide or propylene oxide, in the form of the corresponding ethoxylates or propoxylates. The polyhydric alcohols can also first be converted to the corresponding glycidyl ethers by reaction with epichlorohydrin.

Additional suitable crosslinkers are the vinyl esters or the esters of monohydric, unsaturated alcohols with ethylenically unsaturated C₃-C₆ carboxylic acids, examples being acrylic acid, methacrylic acid, itaconic acid, maleic acid or fumaric acid. Examples of such alcohols are allyl alcohol, 1-buten-3-ol, 5-hexen-1-ol, 1-octen-3-ol, 9-decen-1-ol, dicyclopentenyl alcohol, 10-undecen-1-ol, cinnamyl alcohol, citronellol, crotyl alcohol or cis-9-octadecen-1-ol. An alternative option is to esterify the monohydric, unsaturated alcohols with polybasic carboxylic acids, examples being malonic acid, tartaric acid, trimellitic acid, phthalic acid, terephthalic acid, citric acid or succinic acid.

Other suitable crosslinkers are esters of unsaturated carboxylic acids with the above-described polyhydric alcohols, examples being those of oleic acid, crotonic acid, cinnamic acid or 10-undecenoic acid.

Suitable crosslinkers, furthermore, are straight-chain or branched, linear or cyclic, aliphatic or aromatic hydrocarbons which possess at least two double bonds, which in the case of aliphatic hydrocarbons must not be conjugated, examples being divinylbenzene, divinyltoluene, 1,7-octadiene, 1,9-decadiene, 4-vinyl-1-cyclohexene, trivinylcyclohexane or polybutadienes having molecular weights of 200 to 20 000.

Further suitable crosslinkers are the acrylamides, methacrylamides, and N-allylamines of at least difunctional amines. Such amines are, for example, 1,2-diaminoethane, 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, 1,12-dodecanediamine, piperazine, diethylenetriamine or isophoronediamine. Likewise suitable are the amides formed from allylamine and unsaturated carboxylic acids, such as acrylic acid, methacrylic acid, itaconic acid, maleic acid, or at least dibasic carboxylic acids, of the kind described above.

Furthermore, triallylamine and triallylmonoalkylammonium salts, e.g., triallylmethylammonium chloride or triallylmethylammonium methylsulfate, are suitable as crosslinkers.

Also suitable are N-vinyl compounds of urea derivatives, at least difunctional amides, cyanurates or urethanes, such as of urea, ethyleneurea, propyleneurea or tartaramide, for example, such as N,N′-divinylethyleneurea or N,N′-divinylpropyleneurea.

Further suitable crosslinkers are divinyldioxane, tetraallylsilane or tetravinylsilane. It will be appreciated that mixtures of the aforementioned compounds can also be used. Preference is given to using water-soluble crosslinkers.

Further included among the crosslinking monomers are those which as well as an ethylenically unsaturated double bond contain a reactive functional group, such as an aldehyde group, a keto group or an oxirane group, able to react with an added crosslinker. The functional groups are preferably keto groups or aldehyde groups. The keto or aldehyde groups are preferably attached to the polymer through copolymerization of copolymerizable, ethylenically unsaturated compounds with keto or aldehyde groups. Suitable such compounds are acrolein, methacrolein, vinyl alkyl ketones having 1 to 20, preferably 1 to 10, carbon atoms in the alkyl radical, formyl-styrene, (meth)acrylic acid alkyl esters having one or two keto or aldehyde groups or one aldehyde group and one keto group in the alkyl radical, the alkyl radical preferably comprising a total of 3 to 10 carbon atoms, examples being (meth)acryloxyalkylpropanals, as described in DE-A-2722097. Also suitable, furthermore, are N-oxoalkyl(meth)acrylamides of the kind known, for example, from U.S. Pat. No. 4,226,007, DE-A-2061213 or DE-A-2207209. Particularly preferred are acetoacetyl (meth)acrylate, acetoacetoxyethyl (meth)acrylate and, more particularly, diacetoneacrylamide. The crosslinkers are preferably a compound with at least 2 functional groups, more particularly 2 to 5 functional groups, which are able to enter into a crosslinking reaction with the functional groups of the polymer, especially the keto or aldehyde groups. Functional groups for the crosslinking of the keto or aldehyde groups include, for example, hydrazide, hydroxylamine or oxime ether or amino groups. Suitable compounds with hydrazide groups are, for example, polycarboxylic hydrazides having a molar weight of up to 500 g/mol. Particularly preferred hydrazide compounds are dicarboxylic dihydrazides having preferably 2 to 10 C atoms. Examples of such include oxalic dihydrazide, malonic dihydrazide, succinic dihydrazide, glutaric dihydrazide, adipic dihydrazide, sebacic dihydrazide, maleic dihydrazide, fumaric dihydrazide, itaconic dihydrazide and/or isophthalic dihydrazide. Of particular interest are the following: adipic dihydrazide, sebacic dihydrazide, and isophthalic dihydrazide. Suitable compounds with hydroxylamine or oxime ether groups are specified for example in WO 93/25588.

By appropriate additization of the aqueous polymer dispersion (PD) it is also possible additionally to produce surface crosslinking. Such additization includes, for example, the addition of a photoinitiator, or of siccatives. Suitable photoinitiators are those which are excited by sunlight, examples being benzophenone or derivatives thereof. Suitable siccatives are the metal compounds recommended for aqueous alkyd resins, based for example on Co or Mn (overview in U. Poth, Polyester and Alkydharze, Vincentz Network 2005, p. 183 f).

The crosslinking component is used preferably in an amount of 0.0005% to 5%, more preferably 0.001% to 2.5%, more particularly 0.01% to 1.5%, by weight, based on the total weight of the monomers used for the polymerization (including the crosslinker).

One specific embodiment are polymer dispersions (PD) which comprise no copolymerized crosslinker.

The free-radical polymerization of the monomer mixture (M) may take place in the presence of at least one chain transfer agent (CTA). CTAs are used preferably in an amount of 0.0005% to 5%, more preferably of 0.001% to 2.5%, and more particularly of 0.01% to 1.5% by weight, based on the total weight of the monomers used for the polymerization.

CTAs (polymerization regulators) is a general term for compounds having high transfer constants. CTAs accelerate chain transfer reactions and bring about reduction in the degree of polymerization of the resultant polymers without affecting the overall reaction rate. CTAs may be subdivided into monofunctional, difunctional or polyfunctional agents, depending on the number of functional groups in the molecule that are able to lead to one or more chain transfer reactions. Suitable CTAs are described comprehensively, for example, by K. C. Berger and G. Brandrup in J. Brandrup, E. H. Immergut, Polymer Handbook, 3^(rd) ed., John Wiley & Sons, New York, 1989, p. 11/81-11/141.

Examples of suitable CTAs include aldehydes such as formaldehyde, acetaldehyde, propionaldehyde, n-butyraldehyde, and isobutyraldehyde.

Other CTAs which can also be used are as follows: formic acid, its salts or esters, such as ammonium formate, 2,5-diphenyl-1-hexene, hydroxylammonium sulfate, and hydroxylammonium phosphate.

Further suitable CTAs are halogen compounds, examples being alkyl halides such as tetrachloromethane, chloroform, bromotrichloromethane, bromoform, allyl bromide, and benzyl compounds such as benzyl chloride or benzyl bromide.

Further suitable CTAs are allyl compounds, such as allyl alcohol, functionalized allyl ethers, such as allyl ethoxylates, alkyl allyl ethers or glycerol monoallyl ether.

As CTAs it is preferred to use compounds comprising sulfur in bonded form.

Examples of compounds of this kind are inorganic hydrogensulfites, disulfites, and dithionites or organic sulfides, disulfides, polysulfides, sulfoxides, and sulfones. They include di-n-butyl sulfide, di-n-octyl sulfide, diphenyl sulfide, thiodiglycol, ethylthioethanol, diisopropyl disulfide, di-n-butyl disulfide, di-n-hexyl disulfide, diacetyl disulfide, diethanol sulfide, di-tert-butyl trisulfide, dimethyl sulfoxide, dialkyl sulfide, dialkyl disulfide and/or diaryl sulfide.

Suitable CTAs further include thiols (compounds which comprise sulfur in the form of SH groups, also referred to as mercaptans). Preferred CTAs are mono-, di-, and polyfunctional mercaptans, mercapto alcohols and/or mercapto carboxylic acids. Examples of these compounds are allyl thioglycolates, ethyl thioglycolate, cysteine, 2-mercaptoethanol, 1,3-mercaptopropanol, 3-mercaptopropane-1,2-diol, 1,4-mercaptobutanol, mercaptoacetic acid, 3-mercaptopropionic acid, mercaptosuccinic acid, thioglycerol, thioacetic acid, thiourea, and alkyl mercaptans such as n-butyl mercaptan, n-hexyl mercaptan or n-dodecyl mercaptan.

Examples of difunctional CTAs, comprising two sulfur atoms in bonded form, are difunctional thiols such as, for example, dimercaptopropanesulfonic acid (sodium salt), dimercaptosuccinic acid, dimercapto-1-propanol, dimercaptoethane, dimercaptopropane, dimercaptobutane, dimercaptopentane, dimercaptohexane, ethylene glycol bisthioglycolates and butanediol bisthioglycolate. Examples of polyfunctional CTAs are compounds which comprise more than two sulfur atoms in bonded form. Examples thereof are trifunctional and tetrafunctional mercaptans.

All of the stated CTAs may be used individually or in combination with one another. One specific embodiment relates to polymer dispersions PD which are prepared by free-radical emulsion polymerization without addition of a CTA.

To prepare the polymers it is possible to polymerize the monomers with the aid of initiators that form free radicals.

As initiators for the free-radical polymerization it is possible to employ the peroxo and/or azo compounds customary for this purpose, examples being alkali metal or ammonium peroxidisulfates, diacetyl peroxide, dibenzoyl peroxide, succinyl peroxide, di-tert-butyl peroxide, tert-butyl perbenzoate, tert-butyl perpivalate, tert-butyl peroxy-2-ethylhexanoate, tert-butyl permaleate, cumene hydroperoxide, diisopropyl peroxidicarbamate, bis(o-toluoyl) peroxide, didecanoyl peroxide, dioctanoyl peroxide, dilauroyl peroxide, tert-butyl perisobutyrate, tert-butyl peracetate, di-tert-amyl peroxide, tert-butyl hydroperoxide, azobisisobutyronitrile, 2,2′-azobis(2-amidinopropane) dihydrochloride or 2-2′-azobis(2-methylbutyronitrile). Mixtures of these initiators are suitable as well.

Among the initiators that can be used are reduction/oxidation (i.e., redox) initiator systems. The redox initiator systems are composed of at least one, usually inorganic, reducing agent and one organic or inorganic oxidizing agent. The oxidizing component comprises, for example, the initiators already specified above for the emulsion polymerization. In the case of the reducing component the compound in question comprises, for example, alkali metal salts of sulfurous acid, such as sodium sulfite, sodium hydrogensulfite, alkali metal salts of disulfurous acid such as sodium disulfite, bisulfite addition compounds of aliphatic aldehydes and ketones, such as acetone bisulfite, or reducing agents such as hydroxymethanesulfinic acid and its salts, or ascorbic acid. The redox initiator systems can be used along with soluble metal compounds whose metallic component is able to occur in a plurality of valence states. Typical redox initiator systems are, for example, ascorbic acid/iron(II) sulfate/sodium peroxodisulfate, tert-butyl hydroperoxide/sodium disulfite, tert-butyl hydroperoxide/Na hydroxymethanesulfinic acid. The individual components, the reducing component for example, may also be mixtures—for example, a mixture of the sodium salt of hydroxymethanesulfinic acid with sodium disulfite.

The amount of initiators is generally 0.1% to 10% by weight, preferably 0.1% to 5% by weight, based on all of the monomers to be polymerized. It is also possible to use two or more different initiators in the emulsion polymerization.

The preparation of the polymer dispersion (PD) takes place typically in the presence of at least one surface-active compound. A comprehensive description of suitable protective colloids is found in Houben-Weyl, Methoden der organischen Chemie, volume XIV/1, Makromolekulare Stoffe, Georg Thieme Verlag, Stuttgart, 1961, pp. 411 to 420. Suitable emulsifiers are also found in Houben-Weyl, Methoden der organischen Chemie, volume 14/1, Makromolekulare Stoffe, Georg Thieme Verlag, Stuttgart, 1961, pages 192 to 208.

Suitable emulsifiers are anionic, cationic, and nonionic emulsifiers. As surface-active substances it is preferred to use emulsifiers, whose relative molecular weights are typically below those of protective colloids.

Useful nonionic emulsifiers are araliphatic or aliphatic nonionic emulsifiers, examples being ethoxylated mono-, di-, and trialkylphenols (EO degree: 3 to 50, alkyl radical: C₄-C₁₀), ethoxylates of long-chain alcohols (EO degree: 3 to 100, alkyl radical: C₈-C₃₆) and also polyethylene oxide/polypropylene oxide homopolymers and copolymers. These may comprise the alkylene oxide units copolymerized in random distribution or in the form of blocks. Highly suitable, for example, are EO/PO block copolymers. Preference is given to using ethoxylates of long-chain alkanols (alkyl radical C₁-C₃₀, average degree of ethoxylation 5 to 100) and, of these, particular preference to those having a linear C₁₂-C₂₀ alkyl radical and an average degree of ethoxylation of 10 to 50, and also ethoxylated monoalkylphenols.

Examples of suitable anionic emulsifiers are alkali metal salts and ammonium salts of alkyl sulfates (alkyl radical: C₈-C₂₂), of sulfuric monoesters or phosphoric monoesters with ethoxylated alkanols (EO degree: 2 to 50, alkyl radical: C₁₂-C₁₈) and with ethoxylated alkylphenols (EO degree: 3 to 50, alkyl radical: C₄-C₉), of alkylsulfonic acids (alkyl radical: C₁₂-C₁₈), and of alkylarylsulfonic acids (alkyl radical: C₉-C₁₈). Further suitable emulsifiers are found in Houben-Weyl, Methoden der organischen Chemie, volume XIV/1, Makromolekulare Stoffe, Georg-Thieme-Verlag, Stuttgart, 1961, pp. 192-208). Likewise suitable as anionic emulsifiers are bis(phenylsulfonic acid) ethers and/or their alkali metal or ammonium salts which carry a C₄-C₂₄ alkyl group on one or both aromatic rings. These compounds are general knowledge, from U.S. Pat. No. 4,269,749, for example, and are available commercially, in the form for example of Dowfax® 2A1 (Dow Chemical Company).

Further emulsifiers are the esters—that is, the monoesters and diesters—of phosphoric acid with C₈-C₃₀ alkanols which may have been alkoxylated up to 20 times, especially the monoesters. Frequently the monoesters and the diesters are provided as a mixture alongside one another.

Other suitable emulsifiers are the diesters of phosphoric acid which have been esterified once with a C₈-C₃₀ alkanol, which may have been alkoxylated up to 20 times, and also once with a different C₁-C₃₀ alkanol, preferably with a C₁-C₇ alkanol.

Preferred emulsifiers are compounds of the general formula C_(s)H_(2s+1)O(CH₂CH₂O)_(t)—P(═O)(OH)₂, in which s is 6 to 30 and t is 0 to 20.

Preferred emulsifiers are, for example

Maphos 24 T (C₁₀H₂₁O(CH₂CH₂O)₄—P(═O)(OH)₂) and

Maphos 10 T (2-ethylhexyl phosphate), both from BASF BTC.

Other suitable emulsifiers are the Lutensit® products from BASF SE, such as Lutensit® A-EP (fatty alcohol alkoxylate, phosphoric ester) or else Lutensit® HC9812 (fatty alcohol ethoxylate, phosphoric ester, polymer), for example.

The polymer dispersions (PD) of the invention comprise in general up to 20%, preferably up to 10%, more preferably up to 5%, by weight of at least one emulsifier, based on the total weight of the monomers used in the emulsion polymerization. The polymer dispersions (PD) of the invention generally comprise at least 0.05% by weight, preferably at least 0.1% by weight, of at least one emulsifier, based on the total weight of the monomers used for the emulsion polymerization.

Suitable cationic emulsifiers are preferably quaternary ammonium halides, e.g., trimethylcetylammonium chloride, methyltrioctylammonium chloride, benzyltriethylammonium chloride or quaternary compounds of N—C₆-C₂₀ alkylpyridines, -morpholines or -imidazoles, e.g., N-lauryl-pyridinium chloride.

The amount of emulsifier is generally about 0.01% to 10% by weight, preferably 0.1% to 5% by weight, based on the amount of monomers to be polymerized.

The polymer dispersions (PD) may additionally be admixed with typical auxiliaries and additives. These include, for example, pH modifiers, reductants and bleaches, such as the alkali metal salts of hydroxymethanesulfinic acid (e.g., Rongalit® C from BASF SE), complexing agents, deodorants, flavors, odorants, and viscosity modifiers, such as alcohols, e.g., glycerol, methanol, ethanol, tert-butanol, glycol, etc. These auxiliaries and additives may be added to the polymer dispersions in the initial charge, in one of the feeds, or after the end of the polymerization.

The polymerization takes place in general at temperatures in a range from 0 to 150° C., preferably 20 to 100° C., more preferably 30 to 95° C. The polymerization takes place preferably under atmospheric pressure, although a polymerization under elevated pressure is also possible, such as under the autogenous pressure of the components used for the polymerization. In one suitable version the polymerization takes place in the presence of at least one inert gas, such as nitrogen or argon, for example.

The polymerization medium may be composed either of water alone or of mixtures of water and water-miscible liquids such as methanol. Preferably just water is used. The emulsion polymerization may be carried out either as a batch operation or in the form of a feed process, including staged or gradient procedures. Preference is given to the feed process, in which a portion of the polymerization batch or else a polymer seed is introduced as an initial charge and heated to the polymerization temperature, polymerization is commenced, and then the remainder of the polymerization batch, typically by way of two or more spatially separate feeds, of which one or more comprise the monomers in pure form or in emulsified form, is supplied to the polymerization zone continuously, in stages or under the superimposition of a concentration gradient, with the polymerization being maintained.

The manner in which the initiator is added to the polymerization vessel in the course of the free-radical aqueous emulsion polymerization is known to a person of ordinary skill in the art. It can be included in its entirety in the initial charge to the polymerization vessel, or else employed in stages or continuously in accordance with the rate of its consumption in the course of the free-radical aqueous emulsion polymerization. In each case this will depend, in a manner known per se to a person of ordinary skill in the art, both on the chemical nature of the initiator system and on the polymerization temperature. Preferably a portion is included in the initial charge and the remainder is supplied to the polymerization zone in accordance with the rate of its consumption.

The dispersions that are formed in the polymerization may be subjected, following the polymerizing operation, to a physical or chemical aftertreatment (chemical deodorizing). Examples of such techniques are the known techniques for residual monomer reduction, such as aftertreatment by addition of polymerization initiators or mixtures of two or more polymerization initiators at suitable temperatures; aftertreatment of the polymer solution by means of water vapor or ammonia vapor; or stripping with inert gas; or treatment of the reaction mixture with oxidizing or reducing reagents; adsorption techniques such as the adsorption of impurities on selected media such as activated carbon, for example; or an ultrafiltration, for example.

The aqueous acrylate-alkyd polymer dispersion (PD) typically has a solids content of 20% to 70% by weight, preferably 40% to 65% by weight, based on the polymer dispersion, including water-soluble alkyd resin or aqueous alkyd resin emulsion or polyurethane-alkyd resin emulsion employed.

In one specific embodiment the solids content is 30-55% by weight, preferably 35% to 50% by weight, more preferably 40% to 50% by weight, based on the aqueous acrylate-alkyd polymer dispersion including water-soluble alkyd resin employed or aqueous alkyd resin emulsion or polyurethane-alkyd resin emulsion employed.

The theoretical glass transition temperature, T_(g), of the acrylate portion of the acrylate-alkyd polymer dispersion is preferably less than 50° C. but greater than 20° C., more preferably less than 40° C. but greater than 20° C., more particularly less than 30° C. but greater than 20° C.

The glass transition temperature T_(g) here is the midpoint temperature as determined by differential thermal analysis (DSC) in accordance with ASTM D 3418-82 (cf. Ullmann's Encyclopedia of Industrial Chemistry, 5th Edition, Volume A 21, VCH Weinheim 1992, p. 169, and also Zosel, Farbe and Lack 82 (1976), pp. 125-134; see also DIN 53765).

According to Fox (see Ullmanns Enzyklopádie der technischen Chemie, 4th edition, volume 19, Weinheim (1980), pp. 17, 18), it is possible to estimate the glass transition temperature T_(g). The glass transition temperature of copolymers with low levels of crosslinking, or none, is given at high molar masses, in good approximation, by:

$\frac{1}{Tg} = {\frac{X^{1}}{{Tg}^{1}} + \frac{X^{2}}{{Tg}^{2}} + {\ldots\mspace{14mu}\frac{X^{n}}{{Tg}^{n}}}}$ where X¹, X², . . . , X^(n) are the mass fractions 1, 2, . . . , n and T_(g) ¹, T_(g) ², . . . , T_(g) ^(n) are the glass transition temperatures of the polymers constructed in each case only from one of the monomers 1, 2, . . . , n, in degrees Kelvin. The latter are known, for example, from Ullmann's Encyclopedia of Industrial Chemistry, VCH, 5th edition, Weinheim, Vol. A 21 (1992) p. 169, or from J. Brandrup, E. H. Immergut, Polymer Handbook 3^(rd) edition, J. Wiley, New York 1989.

The hybrid binder of the invention or the aqueous alkyd system can be used as it is or mixed with further, generally film-forming, polymers, as a binder composition in aqueous coating compositions, such as paint or varnish mixtures.

The hybrid binder of the invention can of course also be used as a component in the production of adhesives, sealants, polymeric renders, paper coating slips, fiber nonwovens, and coating compositions for organic substrates, and also for modifying mineral binders.

The photoinitiator used in the hybrid binder of the invention or in the aqueous alkyd system is understood to be, for example, benzophenone or acetophenone or one or more acetophenone or benzophenone derivatives that are not monoethylenically unsaturated, or a mixture of these active ingredients, such as benzophenone/4-methylbenzophenone or 2,4,6-trimethylbenzophenone, for example. Other photoinitiators which are contemplated are described in EP 417 568, at page 3, line 39 to page 7, line 51, hereby explicitly incorporated by reference.

Other photoinitiators which can be used are those which are known to the skilled person, examples being those specified in “Advances in Polymer Science”, Volume 14, Springer Berlin 1974 or in K. K. Dietliker, Chemistry and Technology of UV- and EB-Formulation for Coatings, Inks and Paints, Volume 3; Photoinitiators for Free Radical and Cationic Polymerization, P. K. T. Oldring (ed.), SITA Technology Ltd., London.

Examples of those contemplated include phosphine oxides, a-hydroxyalkyl aryl ketones, thioxanthones, anthraquinones, benzoins and benzoin ethers, ketals, imidazoles or phenyl-glyoxylic acids, or those as described in WO 2006/005491 A1, page 21, line 18 to page 22, line 2 (corresponding to US 2006/0009589 A1, paragraph [0150]), hereby incorporated by reference.

Additionally provided by the invention is a coating composition in the form of an aqueous composition comprising the aqueous hybrid binder of the invention, or the aqueous alkyd system, as defined above.

The hybrid binder of the invention or the aqueous alkyd system is employed preferably in aqueous coating materials. These coating materials take the form, for example, of an unpigmented system (transparent varnish) or of a pigmented system. The fraction of the pigments can be described by the pigment volume concentration (PVC). The PVC describes the ratio of the volume of pigments (V_(P)) and fillers (V_(F)) to the total volume, composed of the volumes of binder (V_(B)), pigments, and fillers of a dried coating film, in percent: PVC=(V_(P)+V_(F))×100/(V_(P)+V_(F)+V_(B)). Coating materials can be divided on the basis of the PVC, for example, as follows:

highly filled interior paint, wash resistant, white/matt PVC=about 85

interior paint, scrub resistant, white/matt PVC=about 80

exterior masonry paint, white PVC=about 45-55

semigloss paint, silk-matt PVC=about 35

semigloss paint, silk-gloss PVC=about 25

high-gloss paint PVC=about 15-25

transparent varnish PVC=<5

These dispersions are used preferably in formulations with a PVC<50, more preferably PVC<40.

Suitable fillers in transparent varnish systems are, for example, matting agents, which thus, desirably, significantly detract from the gloss. Matting agents are generally transparent and may both be organic and be inorganic. Inorganic fillers based on silica are most suitable and are widely available commercially. Examples are the Syloid® products from W.R. Grace & Company and the Acematt® products from Evonik GmbH. Organic matting agents are available, for example, from BYK-Chemie GmbH under the Ceraflour® and Ceramat® brands, and from Deuteron GmbH under the Deuteron MK® brand. Other suitable fillers for emulsion paints are, for example, aluminosilicates, such as feldspars, silicates, such as kaolin, talc, mica, magnesite, alkaline earth metal carbonates, such as calcium carbonate, in the form for example of calcite or chalk, magnesium carbonate, dolomite, alkaline earth metal sulfates, such as calcium sulfate, silicon dioxide, etc. Finely divided fillers are of course preferred in coating materials. The fillers can be used as individual components. In actual practice, however, filler mixtures have proven particularly appropriate, examples being calcium carbonate/kaolin and calcium carbonate/talc. Glossy coating materials generally include only small amounts of very finely divided fillers, or contain no fillers.

Finely divided fillers may also be used to increase the hiding power and/or to save on the use of white pigments. For the adjustment of the hiding power of the hue and of the depth of color, it is preferred to use blends of color pigments and fillers.

Examples of suitable pigments include inorganic white pigments such as titanium dioxide, preferably in the rutile form, barium sulfate, zinc oxide, zinc sulfide, basic lead carbonate, antimony trioxide, lithopones (zinc sulfide+barium sulfate), or colored pigments, for example iron oxides, carbon black, graphite, zinc yellow, zinc green, ultramarine, manganese black, antimony black, manganese violet, Paris blue or Schweinfurt green. Besides the inorganic pigments the emulsion paints of the invention may also comprise organic color pigments, examples being sepia, gamboge, Cassel brown, toluidine red, para red, Hansa yellow, indigo, azo dyes, anthraquinonoid and indigoid dyes, and also dioxazine, quinacridone, phthalocyanine, isoindolinone, and metal complex pigments. Also suitable are synthetic white pigments with air inclusions to increase the light scattering, such as the Ropaque® and AQACeII® dispersions. Also suitable are the Luconyl® products from BASF SE, such as Lyconyl® Yellow, Luconyl® Brown and Luconyl® Red, for example, especially the transparent versions.

The coating composition of the invention (aqueous coating material) may, besides the hybrid binder of the invention or aqueous alkyd system, optionally comprise additional film-forming polymers, pigment, and further auxiliaries.

The customary auxiliaries include wetting agents or dispersants, such as sodium, potassium or ammonium polyphosphates, alkali metal salts and ammonium salts of acrylic acid copolymers or maleic anhydride copolymers, polyphosphonates, such as sodium 1-hydroxyethane-1,1-diphosphonate, and naphthalenesulfonic salts, especially the sodium salts thereof.

More important are the film-forming assistants, the thickeners and defoamers. Examples of suitable film-forming agents are Texanol® from Eastman Chemicals and the glycol ethers and glycol esters available commercially, for example, from BASF SE, under the names Solvenon® and Lusolvan®, and from Dow under the trade name Dowanol®. The amount is preferably <10% by weight and more preferably <5% by weight, based on the formulation as a whole. It is also possible to formulate entirely without solvents.

Further suitable auxiliaries are flow control agents, defoamers, biocides, and thickeners. Suitable thickeners are, for example, associative thickeners, such as polyurethane thickeners. The amount of the thickener is preferably less than 2.5% by weight, more preferably less than 1.5% by weight, of thickener, based on the solids content of the coating material. Further formulating information for wood coatings is described comprehensively in “Water-based acrylates for decorative coatings” by the authors M. Schwartz and R. Baumstark, ISBN 3-87870-726-6.

The coating materials of the invention are produced in a known way by blending the components in mixing apparatus customary for this purpose. It has been found appropriate to prepare an aqueous paste or dispersion from the pigments, water, and, optionally, the auxiliaries, and only then to mix the polymeric binder, i.e., in general, the aqueous dispersion of the polymer, with the pigment paste or pigment dispersion.

The coating material of the invention may be applied to substrates in a typical way, as for example by spreading, spraying, dipping, rolling, knife coating.

The coating materials of the invention feature ease of handling, good processing properties, and high early hardness. Their pollutant content is low. They have good performance properties, such as high water resistance, good wet adhesion, not least on alkyd paints, high blocking resistance, good recoatability, and good flow on application. The equipment used is easily cleaned with water.

The invention is elucidated in more detail by the following, nonlimiting examples.

EXAMPLES Determination of the Solids Content

The solids content (SC) was ascertained generally by drying a defined amount of the aqueous binder (approximately 1 g) to constant weight in an aluminum crucible having an internal diameter of about 5 cm in a drying cabinet at 140° C. Two separate measurements were conducted. The values reported in the examples represent the average of both of the measurements.

Examples 1-3

The water-dilutable alkyd resin WorléeSol® 61E was adjusted beforehand to a solids content of 40% and a pH of approximately 8, using a 25% strength by weight aqueous ammonia solution and deionized water.

The aqueous alkyds WorléeSol® E 150 W and E 280 W were used in the form in which they were received from the suppliers.

Example 4

The following constituents were charged to a polymerization vessel equipped with metering apparatus and temperature regulation:

Initial Charge:

-   -   116 g water     -   19.2 g a polystyrene seed dispersion having a solids content of         33% and an average particle size of 30 nm     -   1.5 g a 15% strength solution of sodium lauryl sulfate         and heated to 85° C. with stirring. Subsequently, with this         temperature maintained, 10% of feed 3 was added, and stirring         was carried out for 5 minutes. Thereafter, feed 1 was metered in         over 180 minutes and, in parallel therewith, the remainder of         feed 3, in 195 minutes.         Feed 1:     -   79.5 g water     -   51.2 g a 15% strength solution of sodium lauryl sulfate     -   117 g n-butyl acrylate     -   97.1 g methyl methacrylate     -   65.5 g styrene     -   13.5 g acetoacetoxyethyl methacrylate         Feed 2:     -   393 g a 40% strength aqueous solution of WorléeSol 61E,         neutralized beforehand with 25% strength aqueous ammonia         solution         Feed 3:     -   72.2 g a 2.5% strength aqueous solution of sodium         peroxodisulfate

When feed 3 was ended, 22.6 g of rinsing water were metered in, and post-polymerization was carried out subsequently for 30 minutes. Feed 2 was metered in over 1 hour, and neutralization took place with 1.81 g of a 25% strength aqueous solution of ammonia.

The dispersion was subsequently cooled and filtered through a 125 μm filter. This gave 1.04 kg of a 45% dispersion.

Example 5

Like example 4, but with the following feed 2: 395 g WorléeSol® E 150 W

Example 6

Like example 4, but with the following feed 2: 416 g WorléeSol® E 280 W

2. Testing of the Aqueous Hybrid Binders

Pendulum Hardness

The coating under test was knife-coated using an Erichsen-film drawing apparatus (300 μm wet) onto a 38×7 cm glass plate. After drying had taken place at room temperature, pendulum measurements were carried out in triplicate at three locations on the glass plate. Measurement took place in accordance with the method of Konig (DIN EN ISO 1522).

EXAMPLES Formulation of the Polymer Dispersion (PD) with Photoinitiator

A stirring vessel was charged at room temperature with 100 g of polymer dispersion (PD) and then with stirring 1% or 2% by weight of Esacure® TZM (from Lehmann & Voss & Co., Germany), a mixture of benzophenone and 4-methylbenzophenone, was added, based on solids content of the respective polymer dispersion, with an afterstir time of 15 minutes.

A film was subsequently drawn down by knife coating and dried for 3 days in the absence of light. The film was then stored further in a light position, and the evolution of the pendulum hardness was monitored by measurements after 24, 72, and 168 hours in each case. The control was the development of hardness in a film of the pure binder.

Example 1 WorléeSol 61 E (Oxidatively Drying, Water-Reducible Alkyd from Worlée)

Pendulum hardness [s] 24 h 72 h 168 h no addition 8 13 23 with 1% by weight 13 22 27 Esacure ®TZM (s/s) with 2% by weight 13 22 29 Esacure ®TZM (s/s)

Example 2 WorléeSol E 150 W (Oxidatively Drying, Water-Based PU Alkyd Emulsion from Worlée)

Pendulum hardness [s] 24 h 72 h 168 h no addition 15 22 34 with 1% by weight 21 28 35 Esacure ®TZM (s/s) with 2% by weight 21 28 36 Esacure ®TZM (s/s)

Example 3 WorléeSol E 280 W (Nonoxidatively Drying, Water-Based PU Alkyd Emulsion from Worlée)

Pendulum hardness [s] 24 h 72 h 168 h no addition 31 28 34 with 1% by weight 31 31 41 Esacure ®TZM (s/s) with 2% by weight 30 32 44 Esacure ®TZM (s/s)

From the results in examples 1 and 2 it is clearly evident that the development of hardness is accelerated when photoinitiator is present.

Example 4 Acrylate/Alkyd Hybrid Using WorléeSol 61 E as Alkyd Portion (Oxidatively Drying, Water-Reducible Alkyd from Worlée)

Pendulum hardness [s] 24 h 72 h 168 h no addition 17 20 34 with 1% by weight 15 23 50 Esacure ®TZM (s/s) with 2% by weight 15 23 59 Esacure ®TZM (s/s)

Example 5 Acrylate/Alkyd Hybrid Using WorléeSol E 150 W as Alkyd Portion (Oxidatively Drying, Water-Based PU Alkyd Emulsion from Worlée)

Pendulum hardness [s] 24 h 72 h 168 h no addition 23 33 46 with 1% by weight 28 38 57 Esacure ®TZM (s/s) with 2% by weight 27 37 53 Esacure ®TZM (s/s)

Example 6 Acrylate/Alkyd Hybrid Using WorléeSol E 280 W as Alkyd Portion (Nonoxidatively Drying, Water-Based PU Alkyd Emulsion from Worlée)

Pendulum hardness [s] 24 h 72 h 168 h no addition 28 27 34 with 1% by weight 28 29 39 Esacure ®TZM (s/s) with 2% by weight 20 35 50 Esacure ®TZM (s/s)

Examples 4-6 as well show very clearly that using the photoinitiator has a significant influence on the development of hardness. 

The invention claimed is:
 1. An aqueous hybrid binder, comprising: (A) from 0.01%-5% by weight of a photoinitiator, based on 100% of the binder; and (B) an aqueous polymer dispersion (PD) comprising a polymer (P) and an alkyd-containing component, wherein: the polymer (P) comprises, in polymerized form, an α,β-ethylenically unsaturated monomer (M), and optionally a further monomer (M1): the alkyd containing component is (a) a water-soluble alkyd resin having a weight-average molecular weight of between 5000 and 40 000 Da, (b) an aqueous alkyd emulsion or dispersion, or (c) a polyurethane-alkyd emulsion or dispersion; and the aqueous polymer dispersion is obtained by a process comprising performing free-radical emulsion polymerization of the α,β-ethylenically unsaturated monomer (M), and optionally the further monomer (M1), to obtain the polymer (P), optionally performing a subsequent chemical deodorization, and adding the water-soluble alkyd resin having a weight-average molecular weight of between 5000 and 40 000 Da, or adding the aqueous alkyd emulsion or dispersion, or adding the polyurethane-alkyd emulsion or dispersion, wherein the addition of the alkyd resin, the alkyd emulsion or dispersion, or the polyurethane-alkyd emulsion or dispersion takes place alternatively (i) directly subsequent to the polymerization of M and M1, and optionally the chemical deodorization, at room temperature, (ii) subsequent to the polymerization of M and M1, with an after stir time of 0-2 h, or (iii) subsequent to the chemical deodorization, with an after stir time of 0-2 h, wherein a temperature of addition according to (ii) or (iii) is from 60 to 99° C.
 2. The aqueous hybrid binder according to claim 1, wherein the photoinitiator is added to the aqueous polymer dispersion which has been cooled to room temperature (23° C.).
 3. The aqueous hybrid binder according to claim 1, wherein the process comprises performing the free-radical emulsion polymerization of the α,β-ethylenically unsaturated monomer (M) and the further monomer (M1) which is at least one combination of monomers selected from the group consisting of: n-butyl acrylate, and methyl methacrylate; n-butyl acrylate, methyl methacrylate, and styrene; n-butyl acrylate, styrene, and butyl (meth)acrylate; n-butyl acrylate, ethylhexyl acrylate, and styrene; n-butyl acrylate, and styrene; and n-butyl acrylate, n-butyl (meth)acrylate, and methyl methacrylate.
 4. The aqueous hybrid binder according to claim 3, wherein the process comprises performing the free-radical emulsion polymerization of the α,β-ethylenically unsaturated monomer (M), the further monomer (M1), and at least one monomer (M2) selected from the group consisting of acrylic acid, methacrylic acid, acrylamide, methacrylamide, acetoacetoxyethyl (meth)acrylate, 2-ureido methacrylate, a methoxypolyethylene glycol monomethacrylate, and a mixture thereof.
 5. The aqueous hybrid binder according to claim 1, wherein the aqueous polymer dispersion (PD) comprises 5-60% by weight of the water-soluble alkyd resin, or the aqueous alkyd emulsion or dispersion, or the polyurethane-alkyd emulsion or dispersion, based on a total weight of the aqueous hybrid binder.
 6. The aqueous hybrid binder according to claim 1, wherein the aqueous polymer dispersion (PD) is an acrylate-alkyd polymer dispersion (PD) comprising an acrylate portion having a glass transition temperature of less than 50° C. but greater than 20° C.
 7. An aqueous alkyd system, comprising the aqueous hybrid binder according to claim 1, wherein the photoinitiator is added to the aqueous polymer dispersion which has been cooled to room temperature (23° C.).
 8. A coating composition in the form of an aqueous composition, comprising: water; the aqueous hybrid binder of claim 1; optionally an inorganic filler, an inorganic pigment, or both; and an auxiliary.
 9. A coating composition in the form of an aqueous composition, comprising: water; the aqueous alkyd system of claim 7; optionally at least one inorganic filler, inorganic pigment, or both; and an auxiliary.
 10. The coating composition according to claim 8, wherein the composition is a coating material.
 11. A process for preparing an aqueous hybrid binder by preparing an aqueous polymer dispersion (PD), the process comprising: performing by free-radical emulsion polymerization of an α,β-ethylenically unsaturated monomer (M), and optionally a further monomer (M1), to obtain a polymer (P); optionally performing a subsequent chemical deodorization; adding a water-soluble alkyd resin having a weight-average molecular weight of between 5000 and 40 000 Da, or adding an aqueous alkyd or polyurethane-alkyd emulsion, wherein the addition of the alkyd resin, alkyd or polyurethane-alkyd emulsion or dispersion takes place alternatively (i) directly subsequent to the polymerization of M and M1, and optionally the chemical deodorization, at room temperature, (ii) subsequent to the polymerization of M and M1, with an after stir time of 0-2 h, or (iii) subsequent to the chemical deodorization, with an after stir time of 0-2 h, wherein a temperature of addition according to (ii) or (iii) is from 60 to 99° C.; and adding 0.01%-5% by weight of a photoinitiator.
 12. A process, comprising applying the aqueous hybrid binder of claim 1 as a binder in a coating material.
 13. A process, comprising applying the aqueous alkyd system of claim 7 in a coating material.
 14. The process according to claim 12, wherein the coating material is a transparent varnish or an emulsion paint.
 15. The process according to claim 12, wherein the coating material is a high-gloss transparent varnish or a high-gloss emulsion paint.
 16. A method of increasing development of early hardness in a coating, the method comprising adding the aqueous hybrid binder of claim 1 in the coating.
 17. A method for increasing development of early hardness in a coating, the method comprising adding the aqueous alkyd system of claim 7 in the coating. 